Download Installation and Troubleshooting Guide

Installation and Troubleshooting Guide
All rights reserved. Reproduction or use of content, in any manner, without express written permission by CDI Electronics, Inc., is prohibited.
Red Lead
Black Lead
Ohms Resistance
DVA
Bank/Cyl
Brown
Brown/Yellow
450-600 ohms
150V +
Stbd (1,3,5)
Brown/White
Brown/Black
450-600 ohms
150V +
Port (2,4,6)
NOTE: If the power pack has no spark on one bank and the readings are good, replace the power pack.
2.
Disconnect the 5-pin connector on the port side of the power pack and see if the spark returns. If it does, use the Fluke meter set to
Ohms and see if the Black/Yellow or Black/Orange wire is shorted to engine ground. Check to see if the Shift Interrupter switch is
located in the circuit where there is no spark.
HIGH SPEED MISS-FIRE OR WEAK HOLE SHOT:
1.
2.
3.
If the engine runs fine until you get above 4900 RPM and then starts missing, check the Orange to Orange/Black power coil wires
with an oscilloscope (If available) or replace the pack. A breakdown inside the pack could cause RFI noise to activate the rev
limiter for no apparent reason.
Using the Piercing Probes and DVA adapter, check the DVA voltage at the RPM where the problem is occurring while connected
as follows:
Red Lead
Black Lead
DVA
Bank/Cylinder
Brown
Brown/Yellow
150V +
Starboard (1,3,5)
Brown/White
Brown/Black
150V +
Port (2,4,6)
NOTE: The readings should rapidly increase as the engine RPM increases and stabilize below 400 volts (voltage exceeding 400
V DVA indicates a bad pack). A sharp drop in voltage right before the miss becomes apparent usually indicates a bad stator
charge coil.
Connect an inductive tachometer to the spark plug wires one at a time and compare the readings. If most of the cylinders show the
same reading and one or two show different readings, check the primary wires with the inductive pickup to see if the readings are
the same coming out of the power pack. A difference in readings between the primary and secondary coil wires indicate bad
ignition wires. No difference indicates a bad power pack.
ONLY HAS FIRE AS LONG AS THE STARTER SOLENOID IS ENGAGED:
Using the Piercing Probes and DVA adapter, check the DVA voltage while connected as follows:
Red Lead
Orange
Black Lead
Orange/Black
DVA
11-24V
NOTE: The readings should rapidly increase as the engine RPM increases and stabilize below 24 volts (voltage exceeding 24 V
DVA indicates a bad pack). A sharp drop in voltage right before the miss becomes apparent usually indicates a bad stator winding.
A sharp drop in voltage when you let off of the starter solenoid indicates a bad power coil on the stator.
ENGINE WILL NOT ACCELERATE OVER 2500 RPM AND SHAKES HARD WHEN OVER 2400 RPM (SLOW
Activated):
1.
2.
3.
4.
Verify the engine is not actually over-heating by using a digital pyrometer.
Check the routing of the tan temperature wires, an example of a bad location is shown below. The tan wires have to be located as
far away as possible from the spark plug wires.
Disconnect the temperature sensors and see if the engine performs normally. If it does, check both temperature sensors and
replace the defective one.
If there is not any indication of a problem at this point, replace the power pack.
Note: Low readings on all checks indicate a possible problem with the flywheel magnets that require checking or low cranking
speed.
Service note: It is recommended that liquid neoprene be applied to the areas where the piercing probes were used.
The OEM power pack may fire with a bad stator power coil while the CDI power pack will not. This is caused by the increased load on
the coil in order to power the digital circuits in the new power pack. If the stator is not replaced in this situation, the stator will fail within a
short time while running and result in an on the water breakdown.
CDI Electronics • 353 James Record Road SW • Huntsville, AL 35824
Web Support: www.cdielectronics.com • Tech Support: 1-866-423-4832 • Order Parts: 1-800-467-3371
All rights reserved. Reproduction or use of content, in any manner, without express written permission by CDI Electronics, Inc., is prohibited.
Rev C • 3/13/13
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